ENGINEERING METALLURGY

1. NON FERROUS METAL
(Other than iron as a major
constituent)
.

2. NON FERROUS MATERIALS
• Elements other than iron
(OR)
• Other than iron is a major constituent
• More costly than ferrous materials
CHARACTERISTICS:
1. Lighter in weight
2. Electrical and thermal conductivity
3. Resistance to corrosion

3. A metal containing little or no iron content
NON-FERROUS METAL
- Aluminum
- Bronze
- Brass
- Copper
- Lead
-Nickel
-Tin

4. Engineering
Materials
Metals
Ferrous
Iron
Steel
Pig iron
Cast iron
Wrought
iron
Non-
Ferrous
Copper &
Alloys
Aluminium
Zinc
Tin
Lead
Non-Metals
Rubber
Plastics
Resin

5. COPPER (செம்பு)
Its a oldest and most widely used non-ferrous metal in
industry. Melting point 1083˚C

6. Copper extraction
•
Copper is converted in to IRON
SULPHIDE and COPPER
SULPHIDE MATTE
OXYGEN INTRODUCED
( Iron sulphide in to Iron oxide)
(COPPER SULPHIDE IN TO
AN IMPURE COPPER)
Impure copper is
purified to pure
copper
Ore ( Copper pyrites) Chemically combined (With
Iron and Sulphur)

8. Properties of copper
• High electrical conductivity
• High thermal conductivity
• Excellent resistance to corrosion
• It’s a soft, ductile and malleable.
• It can be worked in hot and cold condition
• It cannot be welded
• Its become brittle just below its melting
point.

9. Applications of copper
Mostly used in cable
• telephone cables
• Cables for computer network
• Printed circuit boards
• connectors
• Used in the form of sheets and in agriculture
purposes
• Domestic items like vessels
• Used chemical and food industries
• Used as a tubes in heat exchangers.
• Used mainly in the manufacturing of brass and
bronze alloys

10. COPPER ALLOYS
• Copper alloyed with number of elements to
provide a range of useful alloys
Characteristics:
high thermal and electrical conductivity
high corrosion resistance
high ductility and formability

11. Important copper alloys
• Brasses (பித்தளை) ( copper – Zinc alloys)
• Bronze(வெண்கலம்) (copper – Tin alloys)
• Gun Metals ( copper – tin – Zinc alloys )
• Cupro Nickels (copper – nickel alloys)

12. Other elements results
• Small amount of beryllium or chromium to copper give
high strength alloy
• A small addition of cadmium gives a significant
increases in strength with little loss in electrical
conductivity
• Addition of terrilium gives very good machinability

13. BRASS
• Its an alloy of copper(cu) and zinc (zn)
sometimes other elements like tin(sn), lead(pb), aluminium(al)
and manganese(mn) may be added.
Upto 36% of zinc, the brass is a single phase α solid solution
----- These alloys are called α brasses
-These are soft, ductile and easily cold worked
More than 36% of zinc have two phases α and β phases at
room temperature
-- these are stronger than α brasses

14. Brasses

15. Characteristics of brasses
• Its stronger than copper
• Low thermal and electrical conductivity than
copper
• It can be into moulds, drawn into wires, rolled
into sheets and turned into sheets.
• For improving machining property in brass they
are adding 1 – 3% of lead.
• The brass color varies from reddish to white
depend on the amount of zinc present

16. Types of Brasses
Depend on the copper and zinc they are,
• Gliding metal
• Cartridge brass
• Standard brass
• Naval brass
• Admiralty brass
• High tensile brass
• Free cutting brass

18. Bronze
• Its an alloy of copper(cu) and tin (sn)
• They have high strength with corrosion resistance than brass
• The strength of the bronze increase with the increase of tin
content.
• The tin content should be below 12% because they lead to
be brittle
• Bronze can be shaped or rolled into wires , rods and sheets

19. Bronze வெண்கலம்

20. Types of Bronze
• Bell bronze --------- 78 cu, 22 Sn(tin)
• Phosphor bronze – 88 cu, 10 Sn 0.3 P, 1 Zn, 0.7 Pb
• Silicon bronze ------ 95 cu, 3 Si , 1 Mn , 1 Fe
• Aluminium bronze – 89 cu, 7Al, 3.5 Fe, 0.35 Sn
• Coinage bronze ---- 95.5cu, 3 Sn, 1.5 Zn
• Leaded bronze ----- 75 cu, 5 Sn , 18 Pb , 2 Ni

21. BELL BRONZE
• Bell bronze --------- 78 cu, 22 Sn

22. Phosphor bronze
• Phosphor bronze – 88 cu, 10 Sn 0.3 P, 1 Zn, 0.7 Pb

23. Silicon bronze
• Silicon bronze ------ 95 cu, 3 Si , 1 Mn , 1 Fe

24. Aluminium bronze
• Aluminium bronze – 89 cu, 7Al, 3.5 Fe, 0.35 Sn

25. Coinage bronze
• Coinage bronze ---- 95.5cu, 3 Sn, 1.5 Zn

26. Leaded bronze
• Leaded bronze ----- 75 cu, 5 Sn , 18 Pb , 2 Ni

28. Gun Metal
• Gun metals are the alloys of copper(cu), tin(sn) and
zinc(zn)
• Zinc act as a deoxidiser and it improves fluidity during
casting
• Small amount of lead improve
castability and machinability.
• Zinc is cheaper than Tin so
we reduced alloy cost

29. Types of gun metal
1.Admiralty Gun Metal
2.Leaded Gun Metal

31. Cupronickel
• Its a alloy of copper and nickel.
• It’s a single phase uniform solid solution
• Thus all copper nickel alloys are relatively ductile and
malleable.
• They have better corrosion resistance
• It can be hot worked or cold worked.
• It can be shaped by rolling, pressing, drawing and
spinning

32. CUPRONICKEL

33. Types of cupronickels
S.NO ALLOY
NAME
COMPOSIT
ION
PROPERTIES APPLICATIONS
1 Cupronickel 70 Cu, 30 Ni Good corrosion
resistance
Can be cast into
any forms
Salt water piping's ,
condenser tubings
2 Monel Metal 29 cu , 68 Ni
, 1.25 Fe ,
1.25 Mn
Good corrosion
resistance,
Good mechanical
properties
Propellers, pipe
fittings, condenser
tubes, steam turbine
blades, tanks, food
and chemical
industry plants
3 ‘K’ monel 29 cu , 66 Ni
, 2.75 Al, 0.4
Mn, 0.6 Ti
A heat treated
alloy
Good mechanical
properties
Used in motor boat
propeller shafts

34. ALUMINIUM
• It’s a most widely used and important
Non-ferrous material
Characteristics of aluminium:
• Light weight ( 1/3 rd of weight of steel)
• High thermal and electrical conductivity
• Excellent corrosion resistance
• Non – toxicity
• Soft and ductile
• Low specific gravity
• High strength to weight ratio
• High reflectivity.

36. EXTRACTION OF ALUMINIUM
Bauxite
ore
Purification
Dissolved in fused
cryolite(Aluminium and
sodium)
Electrolysis processAluminium

37. Aluminium Vs Copper
• Less cost than copper
• Specific gravity of aluminium 2.7 compared to 8.9
for copper
• Better electrical conductivity (20 % more than
copper)
• But it cannot be welded or soldered.
• To over come this defect they are using tin coating
on aluminium
• Aluminium having low strength, for that its alloyed
with Cu, Ni, Mn, Mg and Si

38. Aluminium alloys
• Aluminium can be alloyed with one or more elements
like Cu, Ni, Mn, Mg and Si
• These elements convert the soft and weak elements into
strong and hard non metal
CHARACTERISTICS:
1. Properties less than steel,
2. Equal to alloys
3. Superior to manganese alloys

39. Types of aluminium alloys
• Heat treatable aluminium alloys
• Non – Heat treatable aluminium alloys

40. Heat treatable aluminium alloys
• Using age or precipitation hardening we cannot
strengthens the aluminum alloy.
• Al – Cu Alloys
• Al – Cu – Ni Alloys
• Al – Mg – Si Alloys
• Al – Li Alloys
• Al – Zn – Cu Alloys

41. Non – Heat treatable aluminium alloys
• These alloys are strengthened by cold working
operations
• Important Non – Heat treatable aluminium alloys
are
• Al – Mn Alloys
• Al – Mg Alloys
• Al – Si Alloys

42. Al –mg sheet

43. Al –Mg alloy
• .

44. Al-Si Alloy
• .

45. Al – Cu Alloys
1.Duralumin
2.Y-alloy

46. AGE or PRECIPITATION
HARDENING
• It’s a process of increasing the strength of an
alloy ( Al – Cu Alloy)
• Step – 1 ------ solution treatment
• Step – 2 ----- - Quenching process
• Step – 3 ------- Ageing Process

48. BEARING ALLOYS
For making bearings

49. Characteristics of a bearing material
• It should have sufficient hardness and wear resistance.
• It should have a low co-efficient of friction.
• It should have a sufficient melting point.
• It should have high thermal conductivity.
• It should have good casting qualities.
• It should have good resistance to corrosion.
• It should be tough , shock resistant and sufficient ductility.

50. Bearing Materials
Widely used bearing materials:
• White metals
• Copper base alloys
• Aluminium base alloys
• Plastic materials
• Ceramics.
• The selection based on loading, running speed
and service conditions.

51. 1) White bearing metal
• Its either tin based or lead based alloys.
• It contain 10% antimony (Sb).
• Tin(sn) + Antimony ---- form a intermetallic compound
SbSn
This form a small hard cubic crystals, termed cuboids.
cuboid is a hard, low friction substance.

52. i) Tin based bearing alloys
• They are called babbit metals.
• Sb 10 % , Sn 82 %, cu 4 %, Pb 4 %
• They are high quality high duty bearing
material than lead based alloys.
• They are used in medium and high duty
applications like in automobile industries.

53. ii)Lead based alloys
• These are cheaper than tin based alloy.
• Sb 13 % , Sn 12 % , Cu 0.75 % , As 0.25% , Pb 74 %
• Used in low pressure low speed applications.

54. 2) COPPER BASED BEARING ALLOYS
• Plain tin bronze -- Cu 85 %, Sn 15 %
• Phosphor bronzes – cu 88%, Sn 10 % P 0.3%, Zn 1%, Pb 0.7%
• Leaded bronzes - Cu 75% ,Sn 5%, Pb 18%, Ni 2%
• Sintered bronzes – Cu powder 90%, Sn powder 10%
• Phosphor bronze gives improved load bearing capacity.
• Leaded bronzes are less strong than other bearing bronzes.
but they will sustain higher loads at higher speeds than white
metal.

55. Uses of copper base bearing alloys
• Used in aero engines,
• Automobile and diesel crank shaft bearings.
• Vacuum cleaners
• Washing machines,
• Extractor fan
• Audio equipments

56. 3)Aluminium based bearing materials
• It contain alloys of tin , copper and nickel
• The expensive tin is replaced by aluminium base
bearing alloys.
• Sn(tin) 5.5 – 7 % , Cu 0.7 – 1.3 % , Ni 0.7 – 1.3 % ,
remaining aluminium
• Used in automobile big end and main bearings.

57. 4) Plastic bearing materials
• 1. Nylons (polymides)
• 2. poly tetra fluro ethylene (PTFE or Teflon)
• They have very low coefficients of friction
• USES
These bearings used in small load applications
Particularly oil lubrication is impossible or undesirable

58. 5) Ceramic Bearing Materials
• These bearings are used in small precision
instruments like jewel bearings in watch
movements
• Alumina used as a bearings in large speed
precision movements.

59. Super alloy
• It is a general term used to describe the nickel
base and cobalt base alloys which have been
developed for use at elevated temperatures.
• Super alloys produce a combination of high
strength at elevated temperatures up to
1000°C and resistance to corrosion.

60. Applications
• Blades for turbine and jet engines
• Heat exchangers, chemical reaction vessel
components and heat treating equipment.